attempts for real time sensing in tribo contacts - ways to ... · motivation 2 10/12/2016 prof. dr....
Post on 09-May-2018
215 Views
Preview:
TRANSCRIPT
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital
Tribology
MENSUS Session Prof. Dr. W. Holweger
Walter.holweger@schaeffler.com
2016-10-11
Agenda
10/12/2016 Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST 1
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
1
2
3
4
5
Motivation
„In Situ“ Chemical Sensors for Life assessment -Principles
In Situ“ Chemical Sensors for Life assessment -Results
Summary
Mechanical Sensors –Sensotect®
Summary
Motivation
10/12/2016 Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST 2
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Components add to the System – Life Cycle of the System creates the
entire Value
Components
System
Product
Motivation
10/12/2016 3
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Components add to the System – Life Cycle of the System creates the
entire Value
System
Components Product Life
Life
Life Cycle
=
Value
Value
Added
Value
Motivation
10/12/2016 4
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
System
Components Product Life
Life
Life Cycle
=
Value
Value
Added
Value
Data aquisition
Engineers Office
Data processing Cloud
=
Digital Twin Dataprocessing
Cognition Map Reactive Maintenance
SCADA Supervisory Control and Data Aquisition
Motivation
10/12/2016 5
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
SYSTEM
System
Components Product Life
Life
Life Cycle
=
Value
Value
Added
Value
Properties
P1
.
.
pn
Properties
P1
.
.
pn
Properties
P1
.
.
pn
Interpreter
Digital twin
of the system
Aim
To change the
component into
a Systems sensor
Example : MEMS
Motivation
10/12/2016 6
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Mechanical Sensors –Sensotect®
10/12/2016 7
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Advantage Sensotect®:
Directly coated Sensor Layer.
No adhesives.
No transfer polymers.
High strain sensitivity.
No aging drift.
No temperature creeping.
Ω
The Component acts as Sensor
Schaeffler Coating Tool Box
Corrotect®
Corrosion Protection Wear Protection
Durotect®
Insulation
Insutect® Triondur®
Sensotect®
Sensor Coating Friction Reduction
Mechanical Sensors –Sensotect®
10/12/2016 8
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Ω
• For strain measurement, a strain sensitive alloy is deposited by advanced PVD (Physical-Vapour-Deposition) technique.
• These structures allow the calculation of the local stress condition, even if they are applied outside of the tribological contact.
Mechanical Sensors –Sensotect®
10/12/2016 9
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Steering shaft
Automotive
Wheel
bearing
Automotive
Bicycle
Bottom bracket
Consumer Products
Thrust Bearing
Industrial
• Application of strain gauges is independent from substrate geometry.
• 3D- as well 2D-applications are state-of-the-art.
Mechanical Sensors –Sensotect®
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital TribologySensotect®
2D-Samples
3D-Bearing
Ω
10/12/2016 10 Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
• Application of strain gauges is independent from substrate geometry.
• 3D- as well 2D-applications are state-of-the-art.
Mechanical Sensors –Sensotect®
10/12/2016 11
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
• High Sensitivity.
• Excellent Linearity und low Hysteresis Deviation.
Torque Measuring Steering Shaft
15,2 15,5
Hysteresis < 0,1 Nm
0,25 % FS
Mechanical Sensors –Sensotect®
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Benefits of Sensotect® Sensor Element:
Modular, standardized design.
High output and low geometry-related risk.
Low unit costs due to low component size.
Sensor Sleeves for Long Shafts
Sensotect® Sensor-Element
> 400 mm
• Cost Reduction by coating small Sensotect Sensor Elements.
10/12/2016 12 Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Mechanical Sensors –Sensotect®
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
0
500
1000
1500
2000
2500
-100 50 200 350 500 650 800 950 1100
Se
ns
or
Sig
na
l [-
]
Torque Reference [Nm]
Sensor Sleeves for Long Shafts
10/12/2016 13 Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
502 503 504
Hysteresis < 0,5 Nm
0,05 % FS
Sensotect® Sensor-Element with
wireless Data Transmission.
Mechanical Sensors –Sensotect®
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
To
rqu
e in
Nm
Time in sec.
Online Torque-Measurement
10/12/2016 14 Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Mechanical Sensors –Sensotect®
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Sensotect enables e.g.
continuous torque-
measurement in e.g.
steering shafts or E-Bikes
during operation.
Complete demonstrator
systems are realized.
Functional Validation
performs excellent
sensitivity, low linearity-
and hysteresis deviation
Function is proven for several
Schaeffler applications.
Sensotect :
Sensor Coating System:
Directly coated strain
gauge system without
polymer adhesives or
transfertape.
Next Steps:
Ready to be developed for series production; search for pilot customer / application
10/12/2016 15 Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
„In Situ“ Chemical Sensors for Life assessment -Principles
10/12/2016 16
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Component Segment
Tribosystem
Take the lubricant as a sensor
Digital Twin Tribosystem
Lubrication
Digital Twin System
Digital Twin Mechanics
(Megatronic)
System and it‘s components
.. And their twins …
Combine to a
„In Situ“ Chemical Sensors for Life assessment -Principles
10/12/2016 17
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Component Segment
Tribosystem
Products pi
Plus
Environmental
noise De
𝐿𝑢𝑏𝑟𝑖𝑐𝑎𝑛𝑡 = 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡𝑠 𝑉𝑒𝑐𝑡𝑜𝑟
C1
.
.
Cn
C11 ……….C1n
.
.
Cn1………….Cnn
Components
(Baseoil, Additives
Components
Self Interaction
C11s ……….C1ns
.
.
Cn1s………….Cnns
Interaction with Surfaces
Take the lubricant as a sensor
p1
.
.
pn
Products
ev1
.
.
ev n
P1 +De
.
.
Pn+De
Environment
Interaction = Self Interaction Interaction with Surfaces
Products Environment
„In Situ“ Chemical Sensors for Life assessment -Principles
10/12/2016 18
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Rolling
element
Life is determined by the distribution of the lubricant within the contact as there are
Cage - Rolling Elements
Rolling Elements toward OR/IR
Life ~ D (t+1)~ 𝐷 𝑡 𝐿𝑖𝑓𝑒 𝑑𝑒𝑝𝑒𝑛𝑑𝑠 𝑜𝑛 𝑡ℎ𝑒 𝑑𝑖𝑠𝑡𝑟𝑖𝑏𝑢𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑢𝑏𝑟𝑖𝑐𝑎𝑛𝑡 over time (t) : D(t) : How much lubricant gets lost – how much does enter again
Example : TRB Test stand
A : Original lubricated
B : After test
A
B
„In Situ“ Chemical Sensors for Life assessment -Principles
10/12/2016 19
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Component Segment
Tribosystem
Take the lubricant as a sensor
Running in Phase
Components merge
Lubricants get distributed
Steady State
Incidential effects
causes lack of lubrication
Metal to metal
Contact – Debris
formation
Sensor How does a
lubricant act in
the presence of
metal and debris
(as a consequence
of starvation)
System in time
In Situ“ Chemical Sensors for Life assessment -Results
10/12/2016 20
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
FE 9 Test Bench for Grease Life
Test bearings DGBB
Support Bearings
Heating elements
Take volatile products
from ageing and detect
by Gas-Chromatography
plus Mass Spectrometry
5.0 10.0 15.0 20.0 25.0 30.0
0.50
0.75
1.00
1.25
1.50
1.75
2.00
2.25
(x100,000)
5.0 10.0 15.0 20.0 25.0 30.0 35.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
(x100,000)
Black : Original
Purple : 50 hours -
Black : Original
Purple : 100 hours -
Some Products
Test Bench
FE9 Grease Life Test
Test benches
Absorption unites
In Situ“ Chemical Sensors for Life assessment -Results
10/12/2016 21
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Adsorption of volatile reaction products
Test benches
Absorption unites
Test unit
Co
nce
ntr
atio
n o
f C
arb
onyl
Co
mp
ound
s
Aldehydes
Aldehydes + Ketones
Ketones
Carboxylic Acids
Failure detected by
friction
„In-situ“ Detection of Catalytic Degradation enables early failure
detected by an increase in friction
Time (hrs)
In Situ“ Chemical Sensors for Life assessment -Results
10/12/2016 22
Attempts for Real Time Sensing in Tribo Contacts - Ways to Digital Tribology
Prof. Dr. Walter Holweger, Basics Tribology ST/ZHZ-ST
Creation of Digital Twins
in Tribosystems
• Mechanical by Strain Gauge units at place
• Chemcial by „in situ“ Spectrometry
Leads to Predictive Reactive Maintenance
Adds to SCADA
Cloud
Cognition Map
Prediction of
Complex Systems
In real time
THANKS for YOUR ATTENTION
top related